Cup brush



July 24, 1956 J. B. BENYAK CUP BRUSH Filed June 16, 1952 IN V EN TOR.JOHN 5 551v YA/C Y mggtw Ri l/01M TTdlf Yg y5 Jjg. 6

United, dtates CUP BRUSH Application June 16, 1952, Serial No. 293,800

8 Claims. (Cl. 15-180) This invention relates as indicated to a novelcup brush, and more particularly to a power driven rotary brush of thistype of unusually strong construction and of a design adapted formanufacture in relatively small sizes.

Cup brushes have long been known in the art and are employed for a Widevariety of purposes, commonly being mounted in drill presses or in powerdriven handheld tools. They are frequently used to remove rust frommetal articles prior to the performance of subsequent finishingoperations and are also used to remove welding flux and spatter after anarc welding operation, for example.

Many different forms of construction of such brushes have been employedin the past with varying degrees of success. Generally, brushes of thistype have been either expensive and strongly made or inexpensive andshortlived due to the manner of assembling the same. In such brushesWhere the brush fill is in the form of twisted tufts, the assembly ofthe brush components has been relatively difiicult and expensive,particularly in the smaller sizes of brushes (Where the brush materialmay protrude for a distance of only one inch, for example).

It is accordingly a principal object of my invention to provide a novelform of cup brush construction which will be very strong and long-livedand yet which is adapted for assembly from its several component partsin a very simple and expeditious manner.

Another objects of this invention is to provide such novel cup brushconstluction in which the bristle retaining element is secured withinthe outer holder or cup member in a fashion to render it substantiallyimpossible of withdrawal.

A further object is to provide such brush assembly in which the brushmaterial, and more particularly such material in twisted tuft form, willbe gripped and sup ported by the constructed neck of an annular channelportion.

Other objects of the invention will become apparent as the descriptionproceeds.

To the accomplishment of the foregoing and related ends, said inventionthen comprises the features hereinafter fully described and particularlypointed out in the claims, the following description and the annexeddrawing setting forth in detail certain illustrative embodiments of theinvention, these being indicative, however, of but a few of the variousWays in which the principle of the invention may be employed.

In said annexed drawing:

Fig. 1 is a top plan view illustrating a preliminary stage in theassembly of my new brush;

Fig. 2 is a perspective view illustrating a subsequent stage in theformation of such brush;

Fig. 3 is a vertical sectional view through the cooperatatent ice ingdie members employed thus to form the Fig. 2 element from the Fig. 1element;

Fig. 4 is a vertical sectional view through the cooperating die membersemployed in the final assembly and forming operation;

Fig. 5 is a vertical sectional View through the finished cup brush asformed by the apparatus of Fig. 4;. and

Fig. 6 is an end view of such finished brush.

Referring now more particularly to such drawing and especially Figs. 1and 2 thereof, a flat sheet metal disc 1 is provided having a pluralityof evenly spaced holes such as 2 punched therein adjacent its outerperiphery and a central opening 3 will also desirably be punched toassist in registering such disc during subsequent steps in the brushassembly. A bundle of brush bristles is then inserted through each ofthe holes 2 and doubled about the outer edge of the disc 50 that bothend portions of such bundle extend in the same generally outwardlyradial direction. It is contemplated that in my new brush such bundlesof brush bristles will ordinarily be of wire and the two end portionswill thereupon be twisted together to form twisted tufts 4.

Such disc may now be placed upon a lower die member 5 with aspring-backed indexing finger 6 protruding upwardly through hole 3 andentering axial opening 7 in upper inner die member 8 which is mountedfor reciprocation within outer upper die member 9 and resiliently hackedby spring 10. Consequently, finger 6 serves both to center disc 1 and toalign the upper and lower die members as the latter are broughttogether, as shown. The upper die member 9 acts to cup disc 1 so thatthe edge portions of such disc including holes 2 are bent into planesgenerally normal to the flat central portion of the disc. The bristletufts 4 will accordingly now extend in generally parallel relationshipto one another as shown in Figs. 26 inclusive. It will, of course, beappreciated that in Figs. 1 and 2 of the. drawing certain of the tuftshave been omitted for the. purpose of greater clarity of illustration.

The cup-shaped element of Fig. 2 is now placed upon another lower diemember 11 generally similar to die 5 and provided with a correspondingindexing finger 12 adapted to pass through center hole 3' of the cuppeddisc 1. A small shoulder 13 is, however, provided in die 11 to support ashort tubular metal element or sleeve 14 longitudinally proportioned sothat the upper edge of such tube will project a short distance beyondthe upper end of die 11.

The cooperating upper die member 15 is formed with a central circularrecess adapted to receive a closely fitting cup member 16 which may beprovided with an axial stem 17 or other means for securing to a drillpress or like machine tool. A spring-backed ball 18 may be mounted indie member 15 to assist temporarily in retaining cup 16 in place withinthe die cavity.

When the dies are now brought together, finger 12 will, of course, bedepressed against the action of its supporting spring 19 and cup 16 willbe forced tightly down upon inner disc member 1. Moreover, since theupper edge portion 20 of tube 14 projects slightly above the upper endof die 11, it will be flanged somewhat radially outwardly to fit tightlyagainst the rounded base of the twisted tufts 4, and the other end oftube 14 will be likewise bulged radially outwardly as at 21 (Fig. 5) aspermitted by the rounded base of such tufts, the bottom loops of suchtufts being of somewhat greater transverse dimensions than the remainingturns or twists for the reason that they must include the edge portionof disc 1. The assembled cup brush may then be removed from the dies andthe outer lip 22 of cup or holder 16 rolled or crimped slightly inwardlyas shown in Fig. 5

to further assist in securing the tufts of bristle material in properposition.

It will thus be seen that the cupped disc 1 to which the bristles areattached is firmly secured within theouter cup or holder 16 and cannotescape therefrom. The central tubular insert 14 fits very tightly withinthe ring of bristle tufts and is, moreover, flanged slightly outwardlyat 20 as above described to prevent its escape from the assembly. Suchinner tubular element, however, is not subjected to any substantialaxial force tending to dislodge the same and serves principally thepurpose of maintaining the twisted tufts in proper axially projectingrelationship. Such inner tubular element 14 cooperates with the wall ofouter cup or holder 16 to form an annular channel Within which thedoubled portions of the twisted tufts are retained and the deformationof the edge portions 21 and 22 aflords a constricted channel neck firmlysecuring and supporting such tufts. Such assembly has been found to bemuch stronger, more rigid and uniform than prior art cup brushes whereinthe twisted tufts have been strung upon a retaining wire, for example.The resilience of the twisted wire tufts where gripped in their baseportions between the wall of holder 16 and tubular element 14 furtherenhances the press fit obtained.

Not only is my new brush extremely satisfactory in operation but also itis relatively simple and inexpensive of manufacture, and a singleoperator may assemble a large number of such brushes in an hours time.When the disc 1 is cupped as shown in Fig. 2, it is found that the edgeof such disc intermediate holes 2 tends to buckle slightly to form anundulating edge with such edge alternately projecting inwardly andoutwardly intermediate such holes and the tufts inserted therethrough.

It will, of course, be appreciated that the disc 1 could be formed tocup shape prior to insertion of the brush material through apertures 2,but assembly is considerably facilitated if performed as previouslydescribed. Also, while I prefer, and my new brush construction isparticularly adapted for, the employment of brush material comprisingbundles of generally parallel metal wires which may be twisted uponthemselves as shown and described, nevertheless in some instances it maybe desired to pass but a single wire through each of the holes 2 withsuch wire then ordinarily being twisted upon itself. Moreover, othercommon brush bristle material may be employed such as horsehair, tampicofiber and the like which will not be twisted upon itself, but only underexceptional circumstances.

If desired, disc 1 may actually be deformed to Fig. 2 shape about innersleeve element 14 but ordinarily a two-step operation is preferred asmore readily controllable. The cupped disc will usually be slightlyflared and is of a size to fit snugly in the socket of the holder, asshown. When used as an end brush, this cup brush has the virtue ofhaving no center to restrict the action of the row of tufts around theouter periphery. Holder 16 may be formed with a threaded socket insteadof the stem 17, or other mounting means may be provided, such beingwell-known in the art.

As best shown in Fig. 5, while lip 22 is generally opposed to inner lip21 it may desirably protrude slightly therebeyond to assist in securingthe inner cylindrical member 14 in place. The inner bottom of cup-shapedholder 16 need not be perfectly flat but may be somewhat concave ifdesired. In eflect, my new cup brush somewhat resembles brushesordinarily termed end brushes, although of course, having no tufts inthe central region. But both the holder and inner member 14 willpreferably be cyclindrical, as shown, and not conical or substantiallyoutwardly flaring.

Other modes of applying the principle of the invention may be employed,change being made as regards the details described, provided thefeatures stated in any of the following claims or the equivalent of suchbe employed.

I therefore particularly point out and distinctly claim as my invention:

1. A cup brush comprising a cup-shaped metal holder, 9. metal dischaving a plurality of holes therethrough symmetrically arranged adjacentits outer periphery, tufts of wire bristle material inserted throughsuch holes and doubled and twisted upon themselves, the outer peripheraledge portion of said disc including such holes being cupped to extendgenerally normal to the body of said disc, with said twisted tuftsextending therefrom generally parallel to one another, said disc andtuft assembly being press-fitted within said cup-shaped holder with saidtufts protruding frorn'the latter, and an inner tubular metal sleevepress-fitted within said cupped disc and engaging the tufts extendingtherefrom, the inner end of said sleeve being flared outwardly to engagebeneath the inner doubled end portions of said tufts and the outer endportion of said sleeve being flared outwardly toward said tufts, theouter lip portion of said cup-shaped holder being turned inwardly tocooperate with said outwardly flared outer end portion of said sleeve toform a constricted neck through which said tufts emerge.

2. A cup brush comprising a cup-shaped metal holder, a metal disc havinga plurality of holes therethrough symmetrically arranged adjacent itsouter periphery, tufts of wire bristle material inserted through suchholes and doubled and twisted upon themselves, the outer peripheral edgeportion of said disc including such holes being cupped to extendgenerally normal to the body of said disc and crimped alternatelyinwardly and outwardly intermediate such holes, with said twisted tuftsextending therefrom generally parallel to one another, said disc andtuft assembly being press-fitted within said cup-shaped holder with saidtufts protruding from the latter, and an inner tubular metal sleevepress-fitted within said cupped disc and engaging the tufts extendingtherefrom, the inner end of said sleeve being flared outwardly to engagebeneath the inner doubled end portions of said tufts and the outer endportion of said sleeve being flared outwardly toward said tufts, theouter lip portion of said cup-shaped holder being turned inwardly tocooperate with said outwardly flared outer end portion of said sleeve toform a constricted neck through which said tufts emerge.

3. A cup brush comprising a cup-shaped metal holder, a metal disc havinga plurality of holes therethrough symmetrically arranged adjacent itsouter periphery, tufts of Wire bristle material inserted through suchholes and doubled and twisted upon themselves, the outer peripheral edgeportion of said disc including such holes being cupped to extendgenerally normal to the body of said disc, with said twisted tuftsextending therefrom generally parallel to one another, said disc andtuft assembly being press-fitted within said cup-shaped holder with saidtufts protruding from the latter, and an inner cylindrical sheet metalsleeve press-fitted within said cupped disc and engaging the tuftsextending therefrom, both the opposed outer lip portions of said holderand sleeve being deformed toward each other to form a constricted neckthrough which said tufts emerge and the inner end of said inner sleeveabutting against said cupped disc.

4. A cup brush comprising a cylindrical cup-shaped metal holder, a flatmetal disc having a plurality of holes therethrough symmetricallyarranged adjacent its outer periphery, tufts of wire bristle materialinserted through such holes and doubled and twisted upon themselves, theouter peripheral edge portion of said disc including such holes beingcupped to extend generally normal to the body of said disc, with saidtwisted tufts extending therefrom generally parallel to one another,said disc and tuft assembly being press-fitted within said cup-shapedholder with said tufts protruding from the latter, and an innercylindrical metal sleeve open at both ends press-titted within saidcupped disc and engaging the tufts extending therefrom, the outer lipportion of at least one of said holder and sleeve being deformed towardthe other to form a constricted neck through which said tufts emerge andthe inner end of said inner sleeve abutting against said cupped disc.

5. A cup brush comprising a cylindrical cup-shaped holder, a fiat dischaving a plurality of holes therethrough symmetrically arranged adjacentits outer periphery, tufts of bristle material inserted through suchholes and doubled upon themselves, the outer peripheral edge portion ofsaid disc including such holes being turned generally normal to the flatbody of said disc, with said tufts extending therefrom generallyparallel to one another and to the axis of said disc, said disc and tuftassembly being tightly fitted within said cup-shaped holder with saidtufts protruding from the latter and an inner cylindrical tubular memberopen at both ends press-fitted within said cupped disc and engaging thetufts extending therefrom, the inner end of said inner tubular memberabutting against said disc.

6. A cup brush comprising a cup-shaped holder having a solid generallyflat inner bottom, a fiat disc having a plurality of holes therethroughsymmetrically arranged adjacent its outer periphery, tufts of bristlematerial inserted through such holes and doubled upon themselves, theouter peripheral edge portion of said disc including such holes beingturned generally normal to the flat body of said disc, with said tuftsextending therefrom generally parallel to one another and to the axis ofsaid disc, said disc and tuft assembly being tightly fitted within saidcupshaped holder with said tufts protruding from the latter and saiddisc flush against said bottom, and an inner tubular member press-fittedwithin said cupped disc and engaging the tufts extending therefrom, thelip of said cup-shaped holder being turned somewhat radially inwardly toassist in retaining said disc and tubular member therewithin.

7. A cup brush comprising a cup-shaped holder, a flat disc having aplurality of holes therethrough symmetrically arranged adjacent itsouter periphery, tufts of bristle material inserted through such holesand doubled upon themselves, the outer peripheral edge portion of saiddisc including such holes being turned generally normal to the flat bodyof said disc, with said tufts extending therefrom generally parallel toone another and to the axis of said disc, said disc and tuft assemblybeing tightly fitted within said cup-shaped holder with said tuftsprotruding from the latter and an inner tubular member press-fittedwithin said cupped disc and engaging the tufts extending therefrom, theinner end of said tubular member being flared outwardiy to engagebeneath the inner doubled end portions of said tufts.

8. The method of forming a cup brush which comprises forming a pluralityof symmetrically spaced holes in a metal disc adjacent the outerperiphery thereof, inserting tufts of wire brush material through suchholes, doubling the end portions of such tufts upon themselves, twistingsuch end portions of respective tufts together to form radiallyextending twisted tufts, deforming such disc to cup shape with suchtufts extending generally parallel to one another and the axis of suchdisc, press-fitting such cupped disc within a cup-shaped holder withsuch tufts protruding therefrom, inserting a tubular member tightlywithin such cupped disc and engaging such tufts extending therefrom,expanding the inner end of such tubular member to engage beneath thedoubled inner end portions of such tufts, expanding the outer endportion of such tubular member more closely to engage such tufts, andturning in the lip portion of such holder opposed to such outer end ofsuch tubular member to form a constricted neck through which such tuftsemerge.

References Cited in the file of this patent UNITED STATES PATENTS1,347,153 Frost July 20, 1920 1,874,475 Ellingham Aug. 30, 19322,062,047 Bickel et al Nov. 24, 1936 2,449,158 Benyak Sept. 14, 19482,480,877 Peterson Sept. 6, 1949

